SKF asset management knowledge prepares coal-fired power plant and hydrocarbon processing plants for maximum reliability and availability

In addition to these key goals, customer’ are helped to define ways to maintain a high efficiency while balancing the needs of personnel safety, environmental protection and optimum fuel use.

One immediate benefit even before a plant goes on-line is a saving of up to 50% from the average anticipated spare parts stock based on vendor recommendations.

In implementation, over 2000 pieces of plant equipment are typically reviewed to determine appropriate maintenance actions allocated in accordance to their criticality to the plants major goals, such as;
* Production and efficiency
* Health and safety
* Environmental impact

The SKF input addresses work processes, technology and organizational needs to ensure a successful delivery of the goals. Software programs are installed and populated with data about the plant machinery in order to monitor equipment health and issue work orders to take remedial action, based on several levels of maintenance attention or potential deterioration in performance. One of these programs, SKF @ptitude Decision Support, is governed by expert logic models created by SKF and the customer and are based on 100 years of SKF knowledge in rotating machinery in process and manufacturing industries

Support systems for maintaining reliability/availability and efficiency are also integrated to ensure ease of managing the equipment condition. These involve formalised documentation of maintenance procedures, actions and effects and include Root Cause Failure Analysis (RCFA) to ensure that the right actions are taken to prevent equipment problems before they impact plant operations and business goals.

Various technologies, tools and systems are used to manage four categories of equipment;
* Critical
* Important; critical but has reserve back up
* Non-critical
* Repair when failed (Run To Failure RTF)

These range from operator inspections with hand held portable vibration data collection systems to permanently installed on-line systems monitoring vibrations, oil analysis etc

Another solution delivered as part of this programme is SKF’s Operator Driven Reliability (ODR), which is a company-wide, team-based process that optimizes the operation of a plant by increasing operator knowledge and actions beyond classic operator duties. ODR impacts equipment effectiveness, contributing to optimal production and financial return on investment. ODR incorporates operational, technical and financial metrics, balanced to best meet the business plan of the enterprise.

Implementing the SKF Operator Driven Reliability solution provides plant benefits in the following areas:
• Smoother running machinery
• Higher production levels
• Higher product quality
• Lower maintenance costs
• Lower energy consumption
• Proactive environment
• Interdepartmental alliances
• A change to a reliability-focused culture

The comprehensive solution delivered by SKF is comprised of process development, task optimization, change management and enabling technology. The enabling technology includes software and hardware specially designed for the challenging conditions within this industry. The hardware is certified to the highest safety standards – ATEX Zone 1 and Class 1, Div 1. The software is populated with templates specific to the equipment used in the hydrocarbon processing industry, speeding implementation and resulting in a faster return on investment. Other software features include:
· Coded notes upon set point exceedence – the right corrective action presented immediately in the operator’s hands
· Conditional points – one observed condition triggers additional data collection to determine the true situation
· Derived points – automatically calculated values based on two or more data points ( i.e. – differential pressure or pump efficiency)